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Doosan DX480LC, DX520LC. Operation and Maintenance Manual (2009) - page 3

CEILING COVER

NOTE:

If the machine is equipped with the optional

transparent ceiling cover never use any chemical

cleaners on its surface. Only use warm water to wash

dust and dirt from its surfaces, and after that, dry it

with a soft fabric towel.

FG000189

Figure 145

Opening the Ceiling Cover

1.

Lower bucket to ground.

2.

Set safety lever (Figure 145) on "LOCK".

3.

Pull the lock (1, Figure 146) in front center of ceiling cover

and push it up with handle.

Closing the Ceiling Cover

1.

Lower bucket to ground.

2.

Set safety lever (Figure 145) on "LOCK".

3.

Pull down cover with the handle (Figure 146) so that the

lock (1) can be locked in the bracket in the ceiling frame.

1

FG000190

Figure 146

Operating Controls

OP000810

2-62

FRONT WINDOWS

WARNING

When leaving operator's seat, set the safety lever to

"LOCK" position (Figure 147), if not a serious accident

could occur by accidentally moving the work levers.

FG000189

Figure 147

Front Upper Window

The front upper window can be housed in the cabin's ceiling.

Opening the Window

WARNING

2

When stowing front window in the cabin roof, make sure

both release levers (1, Figure 148) are latched.

1.

Lower bucket to ground.

1

2.

Set safety lever (Figure 147) on "LOCK".

FG000192

3.

Set engine speed control dial to "LOW IDLE." Allow engine

Figure 148

to idle for three - five minutes.

4.

Shut down engine by turning key to "O" (OFF) position.

5.

Hold the window handles (1, Figure 148), then pull the lock

levers (2) to release the lock. The top of the front window

will come out.

6.

Pull window up, and push it against lock pin at the rear of

the cabin. Make sure that it is securely latched.

7.

Check that lock levers are securely latched in the lock

position.

NOTE:

When the front upper window is open, never

extend your head or body through the window

frame.

NOTE:

If the window happens to fall with a strong

impact against the machine, while some part of

your body is extended out of the cabin, it may

result in bodily injury.

OP000810

Operating Controls

2-63

Closing the Window

WARNING

Be careful that your hands are not caught in window frame.

1.

Lower bucket to ground.

2.

Set safety lever (Figure 147) on "LOCK", and shut down

1

2

engine.

FG000193

3.

Holding upper handles (1, Figure 149) of front window with

Figure 149

left and right-hand, pull lock levers (2, Figure 149) to

release the lock.

4.

Push window forward, and lower it slowly.

5.

When the bottom of the window, reaches the top of the

front bottom window, push the front window to engage the

lock (2, Figure 148).

6.

Check that lock levers are securely latched in the lock

position.

Front Bottom Window

1

The front bottom window can be removed and stored in the rear

of the cabin.

1.

After stowing the front upper window in the cabin ceiling,

remove bottom window (1, Figure 150) from cabin in

direction of the arrow.

FG000194

Figure 150

2.

Set bottom window in rubber holders (2, Figure

151)

behind operator's seat. Secure window with left and right

knobs (3) with push button (4).

3

4

WARNING

2

Never have wet hands when handling a window. Never

drop window or let it come into contact with other

parts of the machine.

FG001345

Figure 151

Operating Controls

OP000810

2-64

DOOR SIDE LATCH

1.

The door side latch (1, Figure 152) is used to secured the

door to the side of the cabin when it is opened.

NOTE:

Keep the door closed and locked when machine

is not in use.

1

FG000196

Figure 152

2.

To release door from side of cabin, push the latch lever (2,

Figure 153) down. The latch lever is to the left of the

operator's seat.

2

FG000673

Figure 153

OP000810

Operating Controls

2-65

CABIN STORAGE

2

COMPARTMENTS

There are two storage compartments behind the operator's seat.

The large compartment

(1, Figure

154) is for storing

nonperishable items.

The covered other one (2, Figure 154) is interconnected with the

air conditioner. So, it can be supplied with either warm or cool air

1

when air conditioner is turned "ON".

FG000209

Figure 154

There is a separate small tray (3, Figure 155) on the right side of

operator's seat.

3

FG000675

Figure 155

ASHTRAY

An ashtray (1, Figure 156) is to the right side of the operator's

1

seat on the side of the cabin. Always close ashtray after putting

out a cigarette.

FG013855

Figure 156

Operating Controls

OP000810

2-66

SUN VISOR

The sun visor can be used to reduce the amount of sunlight

coming through the front window and ceiling.

When wanting to reduce the amount of sunlight coming in the

front window, pull bar (1, Figure 157) down.

2

When not wanting protection, hold the bar with left-hand and

push the release button (2, Figure 157) with right-hand. This will

allow the visor to retract.

1

F

G0

00201

NOTE:

Do not allow the visor to roll back up without holding

Figure 157

it. Not holding it may result in damage to the visor and

retract mechanism.

Ceiling sun visor

(3, Figure

158) slides forward and

backwards.Move it with handle (4) on each side.

4

3

FG000676

Figure 158

When opening the ceiling cover (if equipped), push the sun visor

into its compartment (Figure 159).

FG000204

Figure 159

HANGER

A hanger (1, Figure 160) is located on the upper left side of the

operator's compartment.

WARNING

1

Do not hang anything that will easily fall down, or will

impair your view out of the cabin.

FG000210

Figure 160

OP000810

Operating Controls

2-67

CUP HOLDER

There is a cup holder on the right side of the compartment (1,

Figure 161). Open the access cover and lower it to a horizontal

position.

1

FG000205

Figure 161

DOOR WINDOW HOLDER

1

When the machine is being operated with the cabin door window

opened, window vibration can be reduced by tightening knob (1,

Figure 162) against the window.

FG000206

Figure 162

EMERGENCY GLASS BREAKING

TOOL

The excavator is equipped with a glass breaking tool. It is to the

upper right corner of the cabin. This tool can be used in case of

an emergency situation which requires the breaking of glass to

exit from the cabin. Grip the handle firmly and use the sharp

point to break the glass.

FG000178

WARNING

Figure 163

Protect your eyes when breaking the glass.

Operating Controls

OP000810

2-68

MISCELLANEOUS ACCESS

COVERS AND DOORS

Side Door

Open the side access door and slide prop rod (1, Figure 164) in

slot (2) until it locks at the end of slot.

1

2

FG000165

Figure 164

Battery Box Door

1

Opening

Open door until locking device (1, Figure 165) latches.

Closing

While holding door, press locking device to release lock and

close door.

FG000166

Figure 165

Engine Cover

Open the cover and slide prop rod (1, Figure 166) in the slot (2)

until it locks in notch (3) at the end of slot to support the cover.

2

To close cover, move end of prop rod out of notch so it can slide

in slot.

3

1

FG002081

Figure 166

OP000810

Operating Controls

2-69

Operational Checks Before Starting

Engine

WARNING

When leaving operator's seat, set the safety lever to

"LOCK" (Figure 1) position, if not a serious accident could

occur by accidentally moving the travel or work levers.

FG000211

1.

Set safety lever on "LOCK" (Figure 1).

Figure 1

2.

Fasten seat belt. Check for proper operation and condition.

3.

Set all operation levers in "NEUTRAL."

NOTE:

Be careful not to touch any switches when

starting engine.

4.

Rotate the starter switch to the "I" (ON) position (Figure 2).

Check all indicator lights. A warning buzzer will sound for

about two seconds. After two seconds, all lights except the

O I

following will turn "OFF".

•

Charging warning light

•

Engine oil pressure warning light

•

Engine coolant temperature gauge

•

Fuel gauge

•

Hydraulic oil temperature gauge

FG000084

Figure 2

•

Engine rpm (0 rpm) digital readout

NOTE:

If all of the indicator lights do not come "ON"

when the key is first turned, there is a problem.

OP000811

Operation

3-3

Engine Start

WARNING

Start the engine after sounding horn and making sure that

there are no people or obstacles in the area.

1.

Perform all steps in “Operational Checks Before Starting

Engine” on page 3-3.

2.

Set engine speed control dial slightly above "LOW IDLE"

(Figure 3).

3.

Sound horn.

HAOB34L

Figure 3

4.

Enter password.

NOTE:

If the security system is "LOCKED", a four-digit

password will be required to start the engine. If the

system is "UNLOCKED", no password will be

ENTER

required and this display screen will not appear.

PASSWORD

FG013717

Figure 4

" "

5.

Turn starter switch to

(START) position (Figure 5).

Engine should start in approximately five seconds.

O I

WARNING

If the engine does not start after approximately fifteen

seconds of cranking, release the starter switch. Wait

about five minutes and repeat above step.

6.

After engine has started, release key. Key will return to the

FG000085

"I" (ON) position (Figure 5).

Figure 5

7.

Follow procedures in “Hydraulic System Warm-up” on

page 3-9.

Operation

OP000811

3-4

8.

After warming unit, check all operating indicators to make

4

5

6

7

sure that all engine systems (oil pressure, coolant, etc.) are

in the normal operating range. If any problems are noticed,

CHECK

shut down engine. Normal indicators are:

PWR

1

2

3

FG013731

Figure 6

INDICATOR

No.

INSTRUMENT PANEL LIGHT OR GAUGE

READING

1

Engine Coolant Temperature Gauge

Blue Range

2

Fuel Gauge

Blue Range

3

Hydraulic Oil Temperature Gauge

Blue Range

4

Charging Warning

OFF

5

Engine Oil Pressure Warning

OFF

6

Engine Coolant Temperature Warning

OFF

7

Engine Check Warning

OFF

9.

Check color of exhaust smoke.

•

No color or light blue - Engine is running in good

condition.

•

Black - Incomplete combustion. Check cause.

•

White or dark blue - Engine is burning engine oil.

Check cause.

10.

Check for usual engine vibration and noises. If any are

heard or felt, investigate cause.

NOTE:

If engine coolant temperature gauge pointer

moves into the red zone, the engine coolant

temperature warning light will turn "ON," a

warning buzzer will sound, and the engine

speed will be automatically reduced. Allow the

engine to run at low idle speed until the

temperature gauge registers in the blue zone

again. When the blue zone is reached, allow the

engine to idle for an additional three - five

minutes before shutting down the engine. If not

allowed to idle, heat surge may develop which

will damage the engine. Allowing the engine to

idle will dissipate heat. Check the coolant level,

look for a loose fan belt, inspect for debris

around radiator, and so on.

OP000811

Operation

3-5

Cold Weather Starting

WARNING

DO NOT USE STARTING FLUIDS. The preheat system could

cause the starting fluid to explode. Starting fluids should

never be used.

1.

Perform all steps in "Operational Checks Before Starting

Engine."

2.

Set engine speed control dial slightly above "LOW IDLE"

HAOB34L

(Figure 7).

Figure 7

3.

Sound horn.

4.

Turn starter switch to the "I" (ON) position (Figure 8). When

preheat cycle is completed, the preheat indicator light (1,

Figure 9) will turn "OFF".

O I

FG000084

Figure 8

1

PWR

FG013732

Figure 9

5.

After the preheat completion, immediately turn starter

" "

switch to

(START) position (Figure

10). Engine

O I

should start in approximately five seconds.

WARNING

If the engine does not start after approximately fifteen

seconds of cranking, release the starter switch. Wait

about five minutes and repeat above step.

FG000085

Figure 10

Operation

OP000811

3-6

Connecting the Booster Batteries

1

1.

Shut down engine of the machine on which booster

RED

batteries (3, Figure 12) are mounted.

2.

Connect one end of red cable (1, Figure 12) to the positive

(+) terminal of the machine batteries (4), and the other end

to the positive (+) terminal of the booster batteries.

3.

Connect one end of black cable (2, Figure 12) to the

3

4

negative (-) terminal of the booster batteries (3), and then

BLACK

make ground connection to the upper frame (5) of the

2

machine to be started with the other end of black (-) cable

5

ARO0440L

(2, Figure 12). When making the last connection to upper

frame, be sure to connect the cable end as far away from

Figure 12

the machine batteries as possible. DO NOT CONNECT

DIRECTLY TO THE NEGATIVE BATTERY TERMINAL.

4.

Start the engine.

Disconnecting the Booster Batteries

1.

Disconnect black negative (-) cable (2, Figure 12) from the

machine frame (5) first.

2.

Disconnect the other end of black negative (-) cable (2,

Figure 12) from the booster batteries (3).

3.

Disconnect red positive (+) cable (1, Figure 12) from the

booster batteries (3).

4.

Disconnect red positive (+) cable (1, Figure 12) from the

machine batteries (4).

Operation

OP000811

3-8

Hydraulic System Warm-up

WARNING

If a problem or abnormal operation occurs, immediately

shut down engine. Allow excavator to reach normal

operating temperature before starting work, especially in

cold weather.

The correct operating temperature of the hydraulic oil is 50° -

80°C (120° - 175°F). Make sure to follow the procedures listed

here for hydraulic fluid warm-up.

1.

Run engine for approximately five minutes set at the

middle of the speed range, without a load.

HAOB410L

Figure 13

2.

Set safety lever (1, Figure 14) on "UNLOCK" position.

1

FG000093

Figure 14

3.

Slowly cycle boom, arm and bucket cylinders about five

times without a load to circulate the oil through the system.

Do this for five minutes.

4.

Check for clearance and fully raise the front attachment.

Swing clockwise 3 revolutions. Swing counterclockwise 3

revolutions.

5.

Travel forward and reverse at low speed for two

revolutions of the drive sprocket.

FG000380

Figure 15

OP000811

Operation

3-9

Hydraulic System Warm-up - Cold

Weather

1.

Run engine at "LOW IDLE" (no load) for five minutes

(Figure 16).

HAOB290L

Figure 16

2.

Run engine for approximately five minutes set at the

middle of the speed range, without a load (Figure 17).

HAOB410L

Figure 17

3.

Set safety lever (1, Figure 18) on "UNLOCK" position.

1

FG000093

Figure 18

4.

Slowly cycle boom, arm and bucket cylinders about five

times without a load to circulate the oil through the system.

Do this for five minutes.

FG000380

Figure 19

Operation

OP000811

3-10

5.

Set engine speed control dial to "HIGH IDLE" (Figure 20).

6.

Repeat Step 4 for five minutes. If working speeds continue

to be slow, continue to operate, but use extreme caution

because the machine function may be erratic.

7.

Check for clearance and fully raise the front attachment.

Slowly swing clockwise

3 revolutions. Slowly swing

counterclockwise 3 revolutions.

8.

Travel forward and reverse at low speed for two

revolutions of the drive sprocket.

HAOB550L

Figure 20

OP000811

Operation

3-11

Engine Shut Down

NOTE:

Allow engine to idle for three - five minutes before

shutting down the engine. If not allowed to idle, heat

surge may develop which will damage the engine.

Allowing the engine to idle will dissipate heat.

1.

Park excavator on level and firm ground.

2.

Lower front end attachment to ground and make sure all

operating controls are in "NEUTRAL."

FG000111

Figure 21

3.

Set safety lever on "LOCK" position (Figure 22).

Unlock

Lock

FG001091

Figure 22

4.

Set engine speed control dial to "LOW IDLE" (Figure 23).

Allow engine to idle for three - five minutes.

HAOB290L

Figure 23

5.

Shut down engine by turning key to "O" (OFF) position

(Figure 24).

O I

6.

Remove key from starter switch.

FG000390

Figure 24

Operation

OP000811

3-12

Check and Confirmation After Stopping

Engine

1.

Repair excavator, if there are any coolant or oil leaks.

2.

Inspect front attachment and under carriage for abnormal

appearances. Correct any problems.

3.

Fill fuel tank.

4.

Get rid of any accumulated flammable materials such as

leaves and paper etc. in engine compartment.

5.

Clean all mud, etc. from undercarriage and tracks. Make

sure that all steps and hand holds are clean, and that the

operator's compartment is clean.

SAFETY LEVER

WARNING

When stopping engine or leaving the operator's seat,

"LOCK" the safety lever, otherwise, a serious accident may

occur by accidental movement of travel and work levers.

Whenever leaving the operator's seat, make sure the engine

is shut down and the safety lever is "LOCKED."

Especially, when adjusting the seat, control stands, or

raising the front window, lower window, or ceiling cover,

never forget to lock the safety lever in its "LOCKED"

position.

Be careful not to move the work levers (joysticks) when moving

safety lever.

1.

Push safety lever (Figure 25) down into the "LOCKED"

position. When safety lever is in the "LOCKED" position,

the front attachment, swing and travel movement will be

disabled even though a lever is moved.

Unlock

NOTE:

Lower bucket (front attachment) to ground.

Place all control levers in "NEUTRAL" and shut

down engine, before using the safety lever.

2.

Set safety lever (Figure

25) on "RELEASE/UNLOCK"

position, by pulling it up before starting work.

Lock

NOTE:

When the engine is not running, but the safety

FG001091

lever is "RELEASED" and the starter key is

Figure 25

tuned "ON", moving the work levers (joysticks)

may result in movement. The charged

accumulators in the system will provide pilot

pressure for control valve spool movement.

OP000811

Operation

3-13

TRAVEL

WARNING

1.

Before operating the travel levers, make sure that you

know in which direction the machine is pointing. Look

at the end of the track assemblies. If the drive motors

are visible while sitting in the operator's seat, you are

looking at the back end of the track assembly

(therefore, you are looking backwards). In this case,

the response of the travel levers will be the reverse of

normal operation.

2.

Before moving, make sure that there are no personnel

in the way or on the machine. Sound the horn to alert

workers that you are about to move the machine.

3.

Be sure the path is clear during travel.

4.

Use extreme caution when reversing travel. Be sure

there is a clear path behind the machine.

5.

Make sure to operate the travel control levers

smoothly to avoid sudden starts or stops.

6.

Before leaving the operator's seat, make sure to lock

out all control systems and shut down the engine to

avoid accidental activation.

Automatic Travel Speed Control

WARNING

Do not change the travel mode while traveling. Always use

speed mode "O" when traveling down a slope. It is very

dangerous to change to speed modes indicated "I" or "II"

while going down a slope. Only change travel mode after

coming to a complete stop.

Two travel speed ranges can be selected by using the travel

speed selector switch on the control panel (Figure 26).

O

"O" (LOW) - In this position low travel speed and a higher torque

I

are selected.

II

"I" (HIGH) - In this position high travel speed and a lower torque

are selected.

"II" (AUTOMATIC) - Setting the control at the "II" position

enables the machine to change to a different speed range

automatically. This change happens automatically depending on

the hydraulic oil pressure in the travel circuit. When hydraulic oil

FG000023

pressure rises, the travel speed is automatically set to low. An

example is if the machine is traveling on a flat, solid surface, the

Figure 26

higher speed range would be used. When a slope is

encountered, the speed drops and the travel circuit hydraulic

pressure rises, causing the control circuit to shift to the higher

torque, lower speed range.

Operation

OP000811

3-14

Travel Control Lever Operation

1.

To travel straight (Figure 27), push both travel control

levers/pedals fully forward or backwards. The farther the

levers/pedals are pressed, the faster the travel speed.

NOTE:

"X" is the sprocket end of the track.

"X"

FG000303

Figure 27

2.

Pivot turns (Figure 28) are made by rotating only one track

forward or backward. The machine will pivot on the

nonmoving track.

NOTE:

"X" is the sprocket end of the track.

"X"

FG000304

Figure 28

3.

Spin turns (Figure 29) are made by rotating one track

forward and one track backward. The machine will spin

around its center point, thus counterrotating.

NOTE:

"X" is the sprocket end of the track.

"X"

FG000305

Figure 29

4.

Stopping travel (Figure 30) - Returning travel levers to

"NEUTRAL" position will automatically apply brakes and

stop excavator.

NOTE:

"X" is the sprocket end of the track.

"X"

FG000306

Figure 30

OP000811

Operation

3-15

General Travel Instructions

1.

Set engine speed control dial (Figure 31) on desired

speed.

HAOB550L

Figure 31

2.

Set safety lever on "UNLOCK" position, and folding the

front, raise it 40 - 50 cm (16 - 20 in) above ground. See

Figure 32.

40 ~ 50 cm

FG000123

Figure 32

3.

When possible, travel on firm, level ground. Avoid sudden

movements and sharp turns.

4.

When traveling on rough ground, travel at a slow speed

[1.0 - 1.5 km/h (0.62 - 0.93 MPH)]. Reduced engine speed,

to avoid shock loading the equipment. Be careful that an

excessive force is not added to equipment by touching or

climbing on rocks.

FG000423

Figure 33

Operation

OP000811

3-16

5.

On rough, frozen or uneven terrain, travel slowly.

WARNING

When traveling, keep bucket from 20 - 30 cm (8 - 12 in)

above ground.

Do not travel backward on a slope.

Never turn or travel crosswise on a slope.

Choose a safe alternate route before climbing a slope.

FG000212

If excavator starts to slip or becomes unstable, lower

Figure 34

the bucket immediately into the ground, using it as a

brake.

Avoid working on slopes, because there is a danger of

overturning by becoming unbalance while swinging

and performing front attachment operations.

It is very dangerous to swing towards bottom of slope

with a loaded bucket.

In unavoidable cases level the slope with fill soil, to

make the vehicle as horizontal as possible. See Figure

34.

Do not travel on slopes more than 30° due to turnover

FG000126

danger.

Figure 35

6.

Travel straight up or down slopes, never diagonally across

the slope. See Figure 35 and Figure 36. Extend the arm

and lower the boom to keep the bucket about 20 - 30 cm (8

- 12 in) off the ground. If the machine starts to slide or

becomes unstable, lower the bucket to regain control. If the

engine stalls, lower the bucket, make sure that all controls

are in the neutral position and restart the engine.

NOTE:

Even though engine stops on a slope, do not

operate swing control. The hydraulic

accumulators may cause the unit to swing.

FG000128

NOTE:

Do not open or close operator's door on a slope.

Figure 36

Make sure door is latched.

7.

If dirt or mud builds up in the track frame, raise each track

and rotate and clean that track.

CAUTION

When using the boom and arm to lift any portion of the

machine, roll the bucket until the round base is against

the ground. The angle of the arm to the boom should

be at 90°.

FG000376

Figure 37

OP000811

Operation

3-17

Make sure that the material buildup has been cleared. See

Figure 37 and Figure 38.

8.

The excavator can travel in water that comes up to center

of upper carriage rollers. Make sure that footing is solid so

that the machine will not sink. See “Working in Water” on

90 ~ 110

page 3-29.

NOTE:

If the machine is submerged to the point that

water or mud gets into the swing bearing or

center joint, stop machine operation. Remove

the machine from the submerged location to

FG000345

firm, dry ground. Do not operate until proper

Figure 38

inspection and maintenance have been

completed. Refer to the Shop Manual or contact

your distributor.

Operation

OP000811

3-18

OPERATING INSTRUCTIONS

Engine Speed Control

Engine speed can be manually adjusted using the engine speed

control dial, Increase engine speed by rotating the control knob

clockwise. Decrease engine speed by rotating the control knob

counterclockwise.

IMPORTANT

The engine speed control system has been set at the

HAOA690L

factory and should not require adjustment as part of routine

Figure 39

maintenance.

Mode Selection

More efficient work can be done by choosing a proper power

and work mode combination, suitable to type of work and

conditions. Use the mode selection according to following guide.

Power Mode

1

1.

When the starter switch is turned "ON" the power mode is

automatically defaulted to the standard setting.

2.

Select a proper power mode using button (1, Figure 40)

before starting work.

1

2

3.

When the power mode button (1, Figure 40) is pressed, a

signal sounds, changing the power mode to either "ON" or

"OFF." When the power mode is turned "ON," the symbol

6

7

indicates on the screen.

FG013733

Deactivate the power mode by pressing it a second time.

Figure 40

When the power mode is turned "OFF," the symbol of

standard mode indicates on the screen and the power

mode returns to the standard mode.

Mode

Selection Point

• Required to perform heavy work in a short period of time.

POWER MODE

• Fast speed loading.

• Fast speed travel.

• General work.

STANDARD MODE

• Optimize fuel consumption.

• Light work.

ECONOMY MODE

• Minimize fuel consumption.

• Reduce noise.

OP000811

Operation

3-19

Economy Mode

1.

When the starter switch is turned "ON" the power mode is

automatically defaulted to the standard setting.

2.

Select a proper economy mode using button (2, Figure 41)

before starting work.

1

2

3.

When the economy mode button (2, Figure 41) is pressed,

a signal sounds, changing the economy mode to either

"ON" or "OFF". When the economy mode is turned "ON",

6

7

the symbol appears on the screen.

2

FG013742

Deactivate the economy mode by pressing it a second

time. When the economy mode is turned "OFF", the

Figure 41

symbol of standard mode. Appears on the screen and the

economy mode returns to the standard mode.

Auto Idle Mode

3

1.

The system will automatically reduce engine speed to idle

speed approximately four seconds after all of the control

levers are in the neutral position. When a pilot function is

activated, engine speed is automatically returned to the

1

2

preselected range.

2.

When the starter switch is turned "ON," the work mode is

automatically defaulted to "AUTO IDLE."

6

7

3.

When the symbol is turned "ON," the auto idle function is

activated. Deactivate the auto idle function by again

FG013743

pressing the auto idle selector button (3, Figure 42). At this

Figure 42

time the symbol will be turned "OFF."

WARNING

Turn "OFF' auto idle function when performing work in

close operating area, i.e., work in a narrow area and

loading / unloading on or off a trailer.

Operation

OP000811

3-20

Boost Mode

I

1.

Power boost switch is used to gain maximum digging

O

force.

I

2.

The power boost is activated while the lower button is

being pressed on top of the right-hand work lever

(joystick). The breaker / boost / shear selector switch must

be in the "O" (BOOST) position.

NOTE:

The power boost mode does not affect forward

and reverse travel.

Do not use this switch for more than ten

seconds.

FG000117

Figure 43 RIGHT-HAND WORK LEVER

(JOYSTICK)

OP000811

Operation

3-21

Work Levers (Joysticks) (ISO Style)

1

5

WARNING

3

4

7

8

Check surrounding area before swinging. When operating a

lever while in auto idle, do it carefully, because the engine

speed will increase rapidly.

2

6

NOTE:

When starting work, move work levers (joysticks) slowly

FG000381

and check movement of swing and front attachment.

Figure 44

This equipment is manufactured using the lever configuration

described in ISO standards. Do not change valving, hoses, etc., that

would change this standard. The boom, arm and bucket movements

and swing direction of work levers (joysticks) are as follows:

Left-hand Work Lever (Joystick) (Figure 44 and Figure 45)

1.

Arm dump

4

2.

Arm crowd

1

3

3.

Left swing

2

4.

Right swing

NOTE:

The swing brake is spring applied and

hydraulically released. It is always engaged

when the work lever (joystick) is in "NEUTRAL"

or the engine is shut down.

FG000119

Figure 45

NOTE:

The following is not a mechanical malfunction

but a proper phenomenon of the excavator.

When operating the arm, it may stop

momentarily. When the arm is operated, the

weight of the arm may cause it to move faster

than the amount of oil being supplied.

FG000120

Figure 46

Right-hand Work Lever (Joystick) (Figure 44 and Figure 47)

5.

Boom down

6

6.

Boom up

7.

Bucket crowd

5

8.

Bucket dump

7

NOTE:

Even after stopping the engine, the front can be

8

lowered to the ground by operating work lever

(joystick), by setting safety lever on "UNLOCK"

position and turning starter switch "ON".

FG000121

Figure 47

Operation

OP000811

3-22

Change Machine Control Pattern by Select

Valve (If Equipped)

1

5

WARNING

3

4

7

8

Check surrounding area before swinging. When operating a

2

6

lever while in auto idle, do it carefully, because the engine

speed will increase rapidly.

FG000381

Figure 48

NOTE:

When starting work, move work levers (joysticks)

slowly and check movement of swing and front

<ISO PATTERN>

attachment.

The machine control pattern can easily be changed to the ISO

standard or to the standard backhoe loader hydraulic system

(BHL) by changing the position of the select valve (if equipped).

Use the following procedure to change the position of the select

valve.

The select valve is located in the rear of the cabin.

1.

Rotating spool to the ISO position or to the BHL position.

<BHL PATTERN>

(Figure 49)

FG004954

Figure 49

OP000811

Operation

3-23

Work Levers (Joysticks) (BHL Style)

Left-hand Work Lever (Joystick) (Figure 48 and Figure 50)

2

1.

Boom down

4

2.

Boom up

3.

Left swing

3

4.

Right swing

1

NOTE:

The swing brake is spring applied and

hydraulically released. It is always engaged

when the work lever (joystick) is in "NEUTRAL"

or the engine is shut down.

FG004951

Figure 50

Right-hand Work Lever (Joystick) (Figure 48 and Figure 51)

5.

Arm dump

6.

Arm crowd

5

6

7.

Bucket crowd

8.

Bucket dump

7

NOTE:

The following is not a mechanical malfunction

8

but a proper phenomenon of the excavator.

When operating the arm, it may stop

momentarily. When the arm is operated, the

FG004952

weight of the arm may cause it to move faster

Figure 51

than the amount of oil being supplied.

NOTE:

Even after stopping the engine, the front can be

lowered to the ground by operating work lever

(joystick), by setting safety lever on "UNLOCK"

position and turning starter switch "ON".

FG000120

Figure 52

Operation

OP000811

3-24

OPERATING PRECAUTIONS

WARNING

Do not rest your feet on the travel pedals during normal

machine operation. Unexpected machine travel may occur

in this situation.

1.

Before starting work, investigate terrain and soil condition.

Level ground and drain area if necessary.

2.

Install window guards when working where there is a

possibility of falling rocks or other objects.

FG000374

Figure 53

3.

Check strength of supported structures in advance before

working on them. If insufficient, reinforce it. If any doubt

exists about structural strength, refuse to operate unit.

4.

It is possible that the boom, arm or bucket may come into

contact with the upper or lower structure of the machine.

There are digging conditions which could allow this to

happen.

FG000375

Figure 54

5.

Do not continually "bottom out" the hydraulic cylinders.

Machine damage may occur if the cylinders are fully

extended or retracted, example: arm cylinder fully retracted

and the bucket cylinder is extended to rotate the bucket

into the ground.

FG000132

Figure 55

OP000811

Operation

3-25

6.

Do not use machine travel or swing when the bucket is in

the ground to provide additional breakout force. See Figure

56.

FG000134

Figure 56

7.

Do not use machine weight to provide additional breakout

force. See Figure 57.

8.

When working on soft or muddy ground, make sure that

the machine is not sinking.

FG000137

Figure 57

9.

When working close to the excavated edge, make sure

that the ground the machine is sitting on is solid. Keep the

travel motors (1, Figure 58) to the rear. See Figure 58.

1

FG000677

Figure 58

10. Do not excavate underneath the machine. See Figure 59.

FG000170

Figure 59

Operation

OP000811

3-26

11. Make sure that there is adequate clearance from overhead

electrical supply lines. See Figure 60.

FG000171

Figure 60

12. If the excavation is in an underground location or in a

building, make sure that there is adequate overhead

clearance and that there is adequate ventilation. See

Figure 61.

FG000172

Figure 61

13. Do not use the bucket as a hammer or ramming device.

This is dangerous and causes damage to the front

attachment. See Figure 62.

FG000173

Figure 62

14. Do not dig with the excavator tracks raised. This can result

in structural and mechanical failures.

FG000174

Figure 63

OP000811

Operation

3-27

15. Do not operate travel lever quickly when traveling in high

range.

•

Avoid sudden starts.

•

When traveling in one direction come to a complete

stop before reversing directions. Do not rock

excavator back and forth with levers.

•

Avoid sudden stops. Return levers to neutral by

hand. Do not let them snap back to neutral on their

own.

FG000213

16. If the optional long fronts or attachments or heavy duty

Figure 64

front end attachments are used, the machine balance will

be altered. Follow these additional operating precautions.

WARNING

Do not travel downhill with the front end attachments

raised.

Do not travel across slopes; travel straight up or down

slope.

Use extreme caution when swinging the upper frame

when positioned on a slope.

Allow extra swing stopping room. The additional

momentum generated by the longer or heavier front

end equipment will increase the amount of time

needed to stop the swing motion.

Make sure that all optional equipment has been

authorized and installed properly.

17. Do not move dirt or objects by swinging the excavator into

them. This can result in structural and mechanical failures.

Operation

OP000811

3-28

Working in Water

IMPORTANT

When working in water, do not exceed a slope of more than

15°. If the slope is over 15°, the rear part of the upper

structure will be immersed in water, resulting in radiator fan

damage, and/or engine ECU damage.

FG000179

Figure 65

When working in water, do not operate in water over center of

upper roller (1, Figure 66).

If swing bearing gets wet, immediately grease it until all old

grease is purged from bearing.

If water gets into swing gear housing, drain water immediately

by removing lower inspection cover. Apply new grease.

After working in water, purge old grease on bucket pins.

1

FG000181

Figure 66

OP000811

Operation

3-29

PARKING EXCAVATOR

WARNING

120

Park excavator on firm, level ground. Avoid parking on

slopes. If excavator must be parked on a slope, block tracks

and place bucket teeth in ground. See Figure 67.

FG000214

Figure 67

1.

Park excavator on firm, level ground. Lower bucket to

ground as shown in Figure 68.

FG000111

Figure 68

2.

Set engine speed control dial on "LOW IDLE."

HAOB290L

Figure 69

3.

If you touch the operation lever unintentionally, it may

create a serious accident. Before leaving operator's seat,

set safety lever on "LOCK" position.

Unlock

Lock

FG001091

Figure 70

Operation

OP000811

3-30

TOWING PROCEDURE

Cloth

WARNING

Never use a damaged wire rope or chain. They could brake

and cause a serious accident.

Towing Wire

Always wear gloves when handling a chain or wire rope.

When towing excavator use a wire rope or chain capable of

handling the load.

Attach chain or wire rope to track frame as shown in Figure

71

Insert protective material such as thick cloths between

track frame and wire rope to prevent the wire rope from

being damage.

Towing Wire

FG014876

IMPORTANT

Figure 71

Use shackle hook on track frame to only haul objects that

weigh less than 10 metric tons (11.0 U.S. Tons). Never use it

to haul objects over 10 metric tons (11.0 U.S. Tons).

OP000811

Operation

3-31

Hydraulic Breaker Operation

NOTE:

Hydraulic pressure and flow settings may need to be

changed. Refer to the Maintenance Section of this

manual for further information.

1.

Make sure to read and understand the breaker user's

manual.

2.

Inspect all mechanical and hydraulic connections.

3.

Do not use the breaker as a hammer. See Figure 72.

Do not drop breaker from extreme heights.

The breaker is relatively heavy and drops fast. Do not drop

breaker from extreme heights or damage to upper

structure may result.

FG000188

Figure 72

4.

Do not operate the breaker with the boom or arm cylinders

fully extended (bottomed out). See Figure 73.

Leave over 100 mm (4 in) of clearance between rod end of

cylinder and cylinder head. This will help prevent damage

to cylinders during breaker operation.

FG000191

Figure 73

5.

Do not use the breaker if the hydraulic hoses vibrate

excessively. See Figure 74. Check the breaker's hydraulic

1

accumulator (1) for damage and repair as required. If

excavator is operated under this condition, structural and

hydraulic components can be damaged.

FG000215

Figure 74

OP000811

Operation

3-33

6.

Do not allow the breaker body to go into water if not

equipped for underwater operation. The breaker seal can

be damaged and allow rust, foreign material or water to

enter the hydraulic system and cause damage. Only insert

the breaker tool into water. See Figure 75.

HAOB970L

Figure 75

7.

Do not any lifting or towing with a breaker. See Figure 76.

FG000207

Figure 76

8.

Operate the breaker only to the front and rear of the

excavator. Do not use the breaker to either side of the

excavator. Do not swing the breaker from side to side

when operating it. See Figure 77.

WARNING

Operating a breaker with the upper body turned 90° to

the tracks can result in tipping over the machine or

reduction in service life.

HAOB990L

Figure 77

9.

Do not curl the breaker tool tip into the arm or boom when

traveling or parking the excavator. See Figure 78.

FG000216

Figure 78

Operation

OP000811

3-34

To activate breaker

I

1.

Set breaker selector switch to "II" (BREAKER) position.

O

2.

Press lower button on top of right-hand work lever

I

(joystick) to activate hydraulic breaker.

3.

Release lower button on top of right-hand work lever

(joystick) to deactivate hydraulic breaker.

FG000117

Figure 79 RIGHT-HAND WORK LEVER

(JOYSTICK)

Relief Valve Adjustment

1.

Cap pipe on arm end, using a cap capable of handling 350

kg/cm² under the condition of disconnecting hose to

hydraulic breaker.

2.

Adjust pump pressure using activating the breaker, and

watching the pressure displayed on the instrument panel.

Press the display selector button to show digital pressure

reading. (A separate pressure gauge is not required.)

3.

Adjust the relief valve pressure by turning the adjustment

screw of breaker relief valve. The relief valve is installed on

FG001969

the left side of the upper structure behind the boom. (Do

Figure 80

not use the overload relief valve on the lower part of control

valve for the breaker relief valve.)

WARNING

If the relief valve pressure is adjusted while the

hydraulic breaker is connected, there is possibility

that a high-pressure spike or setting could break a

hose or pipe. Personal injury or death could result

from a hydraulic hose or pipe failure.

OP000811

Operation

3-35

Hydraulic Oil and Filter Service Intervals

When using a hydraulic breaker, the viscosity breakdown and

contamination of hydraulic oil is faster because the work

condition is more severe than during normal digging work. To

prevent the hydraulic components (especially pump) from

having a shortened life cycle, replace the hydraulic oil and main

hydraulic oil return filter using the following schedule.

Attachment

Operation Rate

Hydraulic Oil

Filter

250 Hours (First Replacement)

Bucket Work

100%

2,000 Hours

1,000 Hours (After First Replacement)

Hydraulic Breaker

100%

500 Hours

100 Hours

Work

*

These service intervals only apply, when a genuine DOOSAN oil and filter are used. If any other

brands are used, the guaranteed changed interval should be reduced in half.

100

105

116

551

106

14

4

614

80

FILT

ER

692

112

171

(Firs

t Rep

lacement)

119

214

782

60

128

275

893

HYDRAU

LIC OIL

137

335

1028

40

FILTER

15

6

412

(A

fter F

irst Replacemen

t)

1196

175

500

1400

20

206

63

5

1658

0

500

1000

1500

2000

MACHINE OPERATING HOURS

FG000767

Figure 81

NOTE:

The replacement intervals of hydraulic oil and filter

depend upon the amount of time the hydraulic

breaker is being used. These intervals should be

followed as opposed to regularly scheduled

maintenance.

Operation

OP000811

3-36

ADJUSTING THE PUMP FLOW

NOTE:

For further information, see “Flow Control” on

page 2-44.

1.

On the instrument panel, press the flow control button

, the flow control screen (Figure 82) will be displayed.

2.

Use "UP" (

) or "DOWN" (

) buttons to adjust flow rate.

3.

Press "SELECT" (

) button, to return to normal display

screen and save the flow rate setting.

FLOW CONTROL

E

F

C

H

C

H

1

2

3

4

5

: APPLY

ESC: CANCEL

6

7

8

9

0

<Normal Display>

<Flow Control Display>

FG013831

Figure 82

Flow Control

1-Pump Flow

2-Pump Flow

Step

Setting (l/min)

Setting (l/min)

0

52

1

130

2

160

3

190

4

220

1-Pump Flow +

5

251

300 l/min (79 U.S.

6

281

gpm)

7

311

8

341

9

371

10

399

OP000811

Operation

3-37

Shear Pedal Valve (Optional)

Activating Shear with Pedal Valve

1.

Select "SHEAR" with selector switch on right panel.

1

2.

Make sure that stopper (Figure 85) is in "SHEAR" position.

NOTE:

When stopper is in "SHEAR" position, pedal

valve can be moved/rocked in both directions.

3.

Two-way operation is possible by rocking pedal back and

2

forth between positions (1 and 2, Figure 83). When pedal is

in its center (at rest) position, valve is in "NEUTRAL" and

hydraulic oil flow is stopped.

FG000402

4.

Before operating attachment, be sure to check function

Figure 83

controlled by direction of pedal movement.

Activating Breaker with Pedal Valve

1.

Select "BREAKER" with selector switch on right panel.

2.

Make sure that stopper (Figure 85) is in "BREAKER"

5

position.

NOTE:

When stopper is in "BREAKER" position, pedal

valve can be only moved in one direction.

3.

With the stopper in "BREAKER" position, pedal can only

be pressed in direction (1, Figure 83). When pedal is in its

3

4

center (at rest) position, valve is in "NEUTRAL" and

FG000403

hydraulic oil flow is stopped.

Figure 84

Stopper Positions

The stopper has three positions;

Shear

Breaker

Locked

1.

Rotate knob (3, Figure 84) clockwise in direction of arrow.

The stopper (4) then engages or disengages the pedal

Breaker

bracket (5). The pedal can then function according to

displayed symbol shown by knob rotation.

Lock

Shear

FG014607

CAUTION

Figure 85

When only operating breaker or shear using joystick

button(s), and it is not being controlled by pedal, make

sure stopper is in "LOCKED" position to prevent pedal

from being activated.

Operation

OP000811

3-38

Rotating Pedal Valve (Optional)

1

Attachment Rotating by Using the Pedal Valve

1.

Pressing end (1, Figure 86) is used to turn clockwise.

2.

Pressing end

(2, Figure

86) is used to turn

counterclockwise.

2

NOTE:

Before activating the pedal, be sure to check

the function of the attachment.

FG000405

Figure 86

Locking the Pedal

When rotating is not needed, the pedal can be locked by using

the prop rod (3) locking device.

Locking is completed when the top end of the prop (3) is

3

positioned into pedal hole.

FG000406

Figure 87

A.

Location for "UNLOCKING."

B,

Location for "LOCKING."

A

B

FG000407

Figure 88

Attachment Rotation Using the Left-hand Work Lever

(Joystick)

For a machine equipped with an attachment that rotates,

rotation is activated while one of the control buttons is being

pressed on top of the left-hand work lever (joystick).

There are three buttons on top of the left-hand work lever. The

left and right ones are for controlling rotation.

NOTE:The middle button is for the horn.

Left button is for counterclockwise rotation, and the right one is

FG000035

for clockwise rotation.

Figure 89 LEFT-HAND WORK LEVER

(JOYSTICK)

OP000811

Operation

3-39

OPERATING TECHNIQUES

Lifting

IMPORTANT

There may be local or government regulations, about the

use of excavators for the lifting of heavy loads. Always

contact your local and government agencies in regards to

these regulations.

To prevent injury, do not exceed the rated load capacity of the

machine. If the machine is not on level ground, load capacities

will vary.

Short slings will prevent excessive load swing.

Use the lifting eye on the bucket that is provided to lift objects.

Always try to maintain the lifting eye (Figure 90) straight below

the center line of the arm and bucket pin. In this manner the

weight of the load is being primarily held only by the pin, and not

by the bucket cylinder, link, and link pins.

When a lifting eye is used, the sling/lifting device must be

fastened to the eye in a manner that will not allow it to come

loose.

The most stable position is over the corner of the machine.

For best stability, carry a load as close to the ground and

machine as possible.

HAAD3830

Lift capacity decreases as the distance from the machine swing

Figure 90

center line is increased.

Lifting Unknown Weight

When loads are not accurately known are to be lifted, the person

responsible for the job shall ascertain that the weight of the load

FRON

T LIFT

does not exceed the machine LOAD RATING CHART at the

ZO

N

E

radius at which it is to be lifted.

It is recommended that you feel your way into any lift as a

precaution against tip-over. One method is to position the boom

at 90° over the side of the machine. Slowly lift the load until it

SIDE LIFT

SIDE LIFT

clears the ground. A lift over the side is the most unstable, and

ZONE

ZONE

as the load is swung into the front zone of the excavator it will

become more stable. DO NOT INCREASE SWING RADIUS

AFTER THE LOAD IS LIFTED.

REAR LIFT

ZONE

DANGER

HAAD3842

If a load is picked up from the front zone and swung into the

Figure 91

side zone, a tip-over could result causing a deadly or fatal

injury.

Operation

OP000811

3-40

OP000812

4Inspection, Maintenance

and Adjustment

PREVENTIVE MAINTENANCE

Routine maintenance and inspections are required to keep your

machine in the correct operating condition. The following pages

list the inspection intervals, the system or component checks,

and location references.

NOTE:

The following pages list the service checks and their

required intervals. The service cycles may need to be

shortened depending on the working conditions.

Extremely hot or dusty conditions will require more

frequent service. Operational hours are determined

by the amount of time accumulated on the engine

hour meter on the control console in the cabin.

HAOA601L

Figure 1

NOTE:

Besides the normal hour meter, the multifunction

gauge can be used to keep track of the hours on

individual filters. See “Filter / Oil Info” on page 2-39.

E

F

C

H

C

H

1

2

3

4

5

6

7

8

9

0

FG013662

Figure 2

OP000812

Inspection, Maintenance and Adjustment

4-1

Product Identification Number (P. I. N.)

Location

A P.I.N. number, is stamped on the upper frame, under the

boom foot (Figure

3). It is also stamped on the product

identification plate (Figure 4) on outside of the cabin on right.

NOTE:

Please make note of these numbers and their

locations. These will be required whenever warranty

or service work is requested. Keep this number on

file, incase the machine is stolen.

FG001447

Figure 3

Doosan Infracore Co., Ltd.

7-11, Hwasu-dong, Dong-gu,

Incheon, Korea

FG012987

Figure 4

Inspection, Maintenance and Adjustment

OP000812

4-2

Component Serial Numbers

There are many serial numbers on each traceable components

of the machine. For example, the engine serial number is

stamped on the left side of the engine block, below the rocker

cover. Additional engine information is described on a label

(Figure 6) on the rocker cover.

Please make note of these numbers and their locations. These

will be required whenever warranty service work is requested.

FG001460

Figure 5

FG001479

Figure 6

Safety Precautions

1.

Make sure to lock out the hydraulic controls and post a

notice (Warning Tag) that the machine is being serviced to

prevent any unauthorized operation.

2.

Make sure to clean up any fluid spills, especially around

the engine.

3.

Inspect all fuel lines to make sure that fittings, lines, filters

and O-rings, etc., are tight and are not showing signs of

wear or damage.

4.

If the inspection or test procedure requires that the engine

be running, make sure to keep all unauthorized personnel

away from the machine, and that all industry standard

safety precautions are followed.

OP000812

Inspection, Maintenance and Adjustment

4-3

PRELIMINARY WORK MACHINE

SETUP FOR MAINTENANCE

When performing maintenance specified in this manual, always

park the excavator as follows.

NOTE:

Certain types of maintenance may require the

machine to be positioned differently. Always return

machine to this position.

1.

Park on firm, level ground.

2.

Lower bucket to ground.

FG000111

Figure 7

3.

Set safety lever on "LOCK" position.

Unlock

Lock

FG001091

Figure 8

4.

Allow engine to run at low idle for a minimum of five

minutes to allow engine to cool. If this is not done, heat

surge may occur.

HAOB290L

Figure 9

Inspection, Maintenance and Adjustment

OP000812

4-4

5.

Shut down engine by turning key to "O" (OFF) position.

Remove key from starter switch.

O I

WARNING

If engine must be run while performing maintenance,

use extreme care. Always have one person in the

cabin at all times. Never leave the cabin with the

engine running.

FG000175

Figure 10

6.

Before starting maintenance work, hang up a tag, "Do Not

Touch When Performing Inspection or Maintenance" on

cabin door or work lever.

FG000401

Figure 11

OP000812

Inspection, Maintenance and Adjustment

4-5

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